European Conference Gas Well Deliquification 28-30 September 2009, Hampshire Hotel, The Netherlands Acoustically Determining Plungers Fall Velocity For Different Type Plungers Lynn Rowlan
Plunger Lift System Controller: Controller: Electronic-based system with control parameters to determine under what conditions to exert control by opening/closing the motor valve Transducer: Electronic device that emits an electronic signal to be converted within controller to engineering units Motor Valve: Diaphragm-operated device controlled by controller to open/close sales/tank line Lubricator/Catcher: Uppermost stopping point for plunger; acts as shock absorber; catcher is mechanical device that locks plunger in lubricator for removal and for inspection Arrival Sensor: Magnetic device strapped around lubricator to detect plunger arrivals Vibration sensors have been used Bumper Spring: Shock absorber at plunger s s deepest stopping point Plunger: Pig-type device that provides a seal between gas and liquid inside tubing to deliver fluid and gases to surface with differential pressure. The plunger travels entire length of tubing from catcher to bumper spring.
Plunger Cycle Plunger lift operation cycle can be divided into three parts: 1) Shut-in in: Surface valve closed, flow shut-in, plunger falls down thru gas and liquid in the tubing. Goal of the operator or controller is to try to achieve Shut-in of the well for the shortest amount of time possible, But short enough for plunger to reach bottom. And long enough for f the casing pressure to build high enough to bring the plunger back to surface. 2) Unloading: Surface valve open and pressure stored in the casing lifts the accumulated liquid and plunger to the surface 3) After-flow flow: Surface valve open and well continues to flow after plunger reaches the surface. Plunger held at surface by differential pressure from flow of gas up the tubing. Well is producing gas. Most liquid produced from the formation tends to fall back, accumulating at the bottom of the tubing. The goal of the operator or controller r is to Flow the well only until the well begins to load with liquids.
Pressures During Normal Well Cycle CP TP LP
Shoot Fluid Levels 1) Shoot Fluid Level Down Tubing to Top of Plunger Pressure sensor & microphone 2) Tubing a) Pressure b) Acoustic Signal
Plunger fall speed between two consecutive shots Calculation: T i-1 = 10:55 Plunger Speed equals the difference between the depth to the plunger divided by the difference between the elapsed time. D i-1 = 1972.6 S = (D i - D i-1 ) / (T i - T i-1 ) S = (2860.1-1972.6)/5 1972.6)/5 = 177.5 Ft/Min D i-1 = 2860.1 where: S = Plunger fall speed, ft/sec D i = Distance to the Plunger, ft, at the time of the current shot,t i D i-1 = Distance to the Plunger at the previous time, ft, at time of the previous shot,t i-1 T i = 11:00
Shoot Fluid Level to Top of Plunger to Determine 1) Depth to the Plunger 2) Fall Velocity of a Various Type Plungers 3) If the shut-in time for the well is the shortest time possible 4) Is shut-in time long enough for the plunger to fall to the bottom. Plunger Goes by Collar Plunger Top @ 5001
Worn Brush Plunger 477 fpm Fall
Passive Recording 1) 3 Channel High Frequency (30Hz or greater) Data Acquisition Pressure sensor & microphone 2) Tubing a) Pressure b) Acoustic signal Pressure sensor 3) Casing pressure Just Listen To Plunger
Plunger Falls Slower Through Liquid than Gas 201 Ft/min Gas Plunger on Bottom Plunger Hits Liquid 38 Ft/min Liquid Only Shut-in Time Period Shown
Where s s the Plunger [During Shut-in] Slower Falling through Gas Gradually Slows from 240 ft/min to 135 ft/min Click on Any Point Faster Normal Fall Velocity Profile 1) Tubing is OK 2) Liquid in Bottom Falling thru Liquid
Fall Velocity Increases as Pressure Drops Dual Pad Plunger Increases with Increasing Pressure
Various Plunger Manufacture Features Affecting Fall Velocity 1) Diameter of Plunger 2) Effectiveness of Seal between Plunger and Tubing 3) Increased friction due to contact with the tubing 4) If the plunger falls straight or spins 5) How age/wear effects plunger 6) Valve Opens on Fall to Bypass Fluids
2 3/8 Plungers Types Monitored: Brush Grooved Clean-out Dual Pad Ultra Seal
Comparison of Plungers Falls 2 3/8 Tubing
Comparison Plunger Fall Velocity 2 7/8 Tubing Similar Wells
What do we know? Rowlan, O.L., McCoy, J.N., and Podio, A.L, Determining How Different Plunger Manufacture Features Affect Plunger Fall Velocity SPE 80891, presentation at the SPE Production and Operations Symposium held in OKC,, OK, U.S.A., 23 25 March 2003 1. Measured plunger fall velocities for grooved, ultra seal, dual pad and brush type are much less than 1000 ft/min. 2. Two-Piece & Bypass Plungers are fast! (Generally > 1000 ft/min) 3. Worn 2 3/8 brush type plungers (408-477 477 ft/min). New brush plungers fall slow. Fall Velocity changes w/ wear. 4. 2 3/8 Dual pad type plungers (259-265 265 ft/min). 5. Increasing the diameter from 2.375 to 2.875 resulted in the pad type plunger falling slower (>200 ft/min). 6. Improving the seal on a dual pad plunger (Ultra Seal) results in even slower fall velocities (159 ft/min). 7. Solid Plungers are fast 300-400 Ft/Min. 8. In the same well new plungers fall slower when compared to the same type of older/worn plunger.
Plunger Fall Velocity - Ty Woodworth Three wells Vertical section Straight wells Tubing Condition 2 wells tubing < 1 year old 1 well tubing 7 years old Different fields 26 plungers were evaluated 8 manufacturers 6 designs/styles Pads Single, Double, Triple Brushes Drift, Cut-Down, Oversized Barstocks 2008 The Williams Companies, Inc. All rights reserved.
Plunger Fall Velocity - Barstocks 550 500 Well 1 Well 2 Well 3 450 400 Fall Velocity (ft/min) 350 300 250 200 150 100 50 0 Mega Lift Barstock PCS 16" Barstock Weatherford Barstock Sand Viper Superior Sand Barstock 2008 The Williams Companies, Inc. All rights reserved.
Conclusions Adjusting cycle times to a specific plunger will yield more efficient plunger operation and increased gas production Various styles of plunger types fall at different velocities i.e. single pad vs. double pad Different manufacturers fall at different velocities i.e. FB Brush vs. Mega Brush Age of tubing did not seem to have an affect? Tubing gas flow into tubing? 2008 The Williams Companies, Inc. All rights reserved.
Plungers Tested in 2 3/8 Tubing
Observations Solid plunger that fell the 2nd fastest also had the most gas that slipped past the plunger probably due to poorest seal. Solid Plungers were less than 100% Efficient Padded Plungers fell slower and tended to have the highest liquid efficiencies Good Seal resulted in liquid measured at the surface higher than the liquid at the bottom of the tubing above plunger when surface valve opened Most likely due to liquid below the SN in the casing being brought into the tubing when unloading begins.
Deviated Well Impacts Velocity Plunger Slowed from 200 ft/min once plunger goes past Kick off Point 8234 Ft What Effect Does Wellbore Deviation Have on Plunger Fall Velocity?
Plunger Velocity Slows Past Hole Plunger Slowed from 217 ft/min When Falls Past Hole@ 5050 Liquid in the bottom of the tubing provides a pressure seal
Actions by the Plunger Displayed in the Tubing Pressure Increase in Tubing Pressure and/or Gas Flow Rate Past Plunger Results in Plunger Slowing Down 80.0 0 78.0 Tubing Pressures - (psi) 76.0 74.0 72.0 70.0 68.0 66.0 64.0-100.0-200.0-300.0-400.0 Plunger Velocity - (ft/min) 62.0 1.212 4.684 8.157 11.629 15.101 18.573-500.0 Elapsed Time - minutes 60.0 0 Tubing Gas Flow Rate - (Mscf/D) 40.0 20.0 0-20.0-40.0-60.0-80.0-100.0-120.0-140.0 Increase in Gas Flow Rate -160.0 1.212 4.684 8.157 11.629 15.101 18.573 Elapsed Time - minutes Plunger Slows Down -100.0-200.0-300.0-400.0-500.0 Plunger Velocity - (ft/min)
Paraffin Stops Plunger Fall Plunger Knocked Loose by Acoustic Pulse Blast from Gas Gun Re-Starts Fall Tubing Pressure Signal Becomes Flat when Plunger Sticks
Chemical Treatment Down Tubing Tends to Slow/Stops Plunger Fall Plunger Does Not Reach Bottom Fast Plunger Arrivals are a Symptom of Sticking Plunger
2 7/8 inch Bypass Plunger w/ Standing Valve Hits at Bottom Very Hard [A] [1] [2] [B] [3][4] [C 70.0 60.0 Fell 5339 Ft in 1.73 Min 3083 ft/min Rise Velocity 556 Ft/Min 50.0 40.0 Tubing Casing 30.0 20.0 Below Critical, Gas Velocity 44.7 ft/sec Gas Flow Rate: 5000 m3/d 176.6 MscfD Line Pressure 30 Psia 10.0 10.431 13.903 17.376 20.848 24.320 27.792
2 7/8 inch Bypass Plunger Fall Velocity Range 5000-1000 ft/min 0-1000 Fall Velocity Averaged 3654 Ft/Min 0 1200 Plunger Fall Velocity - Ft/Min -2000-3000 -4000? Fell 5339 Ft in 1.73 Min 3083 ft/min 2400 3600 Depth to Plunger - Feet 60 MPH 4800-5000 Plunger Hits Liquid - 5242.71 Ft Bottom of Tubing - 5339.24 Ft -6000 6000 10.417 10.764 11.111 11.458 11.806 12.153 12.500 Elapsed Time - Mins
Fall Velocity Bypass Valve Closes Plunger Slowed from 950 ft/min to 366 ft/min due to Valve Premature Closing @ 3016 Bypass Valve Closed By-pass Plungers Just don t t Work in my wells. Why?
Recommendation 1) DETERMINE PLUNGER FALL VELOCITY - accurately measure using an acoustic fluid level instrument. 2) DETERMINE MINIMUM SHUT-IN TIME to maximize the number of cycles per day. 3) DON T T WASTE TIME GUESSING - Track plunger fall to ensure plunger reaches fluid at bottom of the tubing by the end of the shut-in period. 4) MAXIMIZE PRODUCTION from plunger lift installations by using the shortest possible shut-in time equal to the time required for the plunger to reach bottom.
Questions?